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Reluctant Project - Cooley Barn Find

chuck hahn said:
Greg has done the tilte work and its in his name now...as i understand things he has done the Bonded title in Texas. This puts the bike in his name and makes him the legal owner.
Click to expand...

That was an interesting story actually. I bought the bike from a guy who found it in the barn of an old church property he purchased at a government auction.

The owners of the church property were both deceased. I did some title search work on the bike and found that the bike had been registered in Texas to a guy who died about 10 years ago. The bike had not been registered many years before that.

The really interesting coincidence is that the guys last name was Billingsley, and my last name is Billingsly.
 
Todays progress report:::::


New wheel bearing installed
Wiring harness reinstalled
Got the right handle switch mounted and put on the Frank Z. decals.
Got the sprockets and chain mounted and adjusted.
Valves checked and adjusted.
Decals for the dash indicator lights put on...looks darn good too
Put the clutch safety switch in the perch and ran the clutch cable up to the perch also. Still need to organize the wires in the battery box compartment and zip tie it all nice and neat...Sundays project.

GregsCooley020.jpg

GregsCooley019.jpg

GregsCooley023-1.jpg

GregsCooley022-1.jpg

GregsCooley021.jpg
 
WELL DONE ! I am surprised how good those controls decals look. It is as if they were painted in there.
 
ged said:
Chuck did you get the dash decals off frank z like the right handle switch?
Click to expand...

actually I did not. I didn't realize someone here had them. I got them off ebay pretty cheap from across the pond for about $12 shipped to my door.

SUZUKI GS400 GS550 GS750 GS850 GS1000 CONSOLE RESTORATION DECAL SET

SUZUKI GS400 GS550 GS750 GS850 GS1000 CONSOLE RESTORATION DECAL SET See original listing


 
4 hours of seat stripping, skim coating the small rusty pits with bondo and sanding. Then took the sprocket cover outside to start polishing it and saw that the lower front corner was snapped off..cant win for loosing somedays!!!

Wire wheel on the angle grinder to clean up the foam side of the pan. Had some pretty good divits in it but thats all gonna be covered by the foam anyways. Still one really solid pan though.


xxxxx012.jpg

xxxxx011.jpg

xxxxx010.jpg
 
Last edited:
Fresh from the box..

Fresh from the box..

Vance and Hines 4 into 1 arrived today. Had to go get new bolts and got it all mounted up. Looking like one heck of a SWEET SWEET ride now.

xxxxx013.jpg

xxxxx014.jpg

xxxxx015.jpg

xxxxx016.jpg
 
Love the Vance and Hines look, I just got a set for the sons bike and they came with black coloured header bolts. Can I please ask why you got new bolts, was it because of the colour?
 
There wasnt any hardware with them that i saw in the box and the other original ones were all rusty and pitted so new bolts were in order.
 
Put new shrink tubing on the left hand switch leads and ran the harness down to the proper area. Then put the coils in and zip tied everything nice and neatly.

Goona do some more this weekend after I get the cam cover rehabbed and painted. Then thats pretty much it and I can go for a after build restart.
 
Polished up the headlight chrome rim and got the front brake switch installed. Got everything zip tied up nice under then tank area. Gonna blast the cam cover tomorrow afternoon and paint it..then should be about ready for a restarting of the engine.
 
It's a good feeling getting to this point, eh, Chuck? It's been cool watching the process. You've done a nice job on this S. Anxious for the fire up..
 
Me too Larry. Aaron has your pics with the measurements and he was over last night with a note pad, camera, and tape measure to do even more study.

Should have the body kit back soon. Gonna get the cam cover done today and Sunday will be fire it up day. Gonna run it thru several heat /cool cycles with increasing heating time to slowly bake the engine paint and avoid any bubbling. Gotta do this step patiently...
 
Painter is shooting the tins this afternoon far as I know. Got an issue with the decal kit though..only has the black stripe in it. My Cooley has the black and white stripes as one decal which is then cleared over. Some sorting with this kickup and then proceed.
 
Cam cover has just been painted. Put the carbs and airbox in and go for a start at some point tomorrow!!! Gonna try and post a video too..
 
And we have a runner again

And we have a runner again

Got her fired off.. Hopefully this link will allow you to see the video. Click on the picture and it should redirect to the video.

 
Last edited:
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